GILLAM - FEi

Written by : J. Bonardot / K. Flammang Date : 05/08/2011 Ref. Doc. : 4722JB-KFbf Revision : 3 GILLAM - FEi SA Mont Saint-Martin 58 4000 LIEGE �: (+32) 4/232 95 95 - Fax: (+32) 4/223 42 76 BELGIUM

E-mail : info@gillam-fei.be Internet : www.gillam-fei.be

IDC20K

Current generator for testing railway circuit-breakers

User Guide

GILLAM - FEi

4722JB-KFbf – Rev. 3 IDC20K – Current generator for testing 05/08/2011 railway circuit breakers – User Guide

REV. DATE SUBJECT MODIFIED

PAGES

0 13/04/11 First release

1 14/04/11 Addition of software part 3,8�12

2 15/04/11 Revision of software part

3 05/08/2011 Addition of language configuration (§3.7) 6-8

HISTORY SHEET

GILLAM - FEi

4722JB-KFbf – Rev. 3 IDC20K – Current generator for testing 05/08/2011 railway circuit breakers – User Guide

TABLE OF CONTENTS

1. Introduction....................................................................................................................... 1

1.1. Equipment presentation ......................................................................................................1

1.2. Contents of this user guide ..................................................................................................1

2. Equipment Description ..................................................................................................... 2

2.1. The ICK20 control module..................................................................................................2 2.1.1. A Man Machine Interface................................................................................................................ 2 2.1.2. A control module situated in a 2U rack........................................................................................... 2

2.2. IJK20 injection modules ......................................................................................................3

2.3. Connection ............................................................................................................................3

3. software Description.......................................................................................................... 5

3.1. Starting-up ............................................................................................................................5

3.2. The menu...............................................................................................................................6

3.3. Injectors status .....................................................................................................................6

3.4. Current curve loading..........................................................................................................7 3.4.1. Parameterizable function loading .................................................................................................... 7 3.4.2. File loading...................................................................................................................................... 7

3.4.2.1. Files format............................................................................................................................ 7 3.4.2.2. File opening ........................................................................................................................... 7

3.5. Current curve injection .......................................................................................................8

3.6. Curve saving .........................................................................................................................8

3.7. Language configuration.......................................................................................................8

3.8. Curves display configuration ..............................................................................................9

3.9. Calibration ............................................................................................................................9

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1. INTRODUCTION

1.1. Equipment presentation

The current injector (IDC20K) is a modular designing equipment aimed at testing circuit-breakers used in high voltage direct current traction networks, or any other intense direct current equipment. Tests are performed on insulated devices of the traction network, by injecting by means of large section cables an arbitrary shape current, with a maximum value of 20000A and a maximum duration of 500ms. A standard 230V 16A main supply switch is required for its power supply.

1.2. Contents of this user guide

• Equipment description

• Sub-assemblies connection instructions

• Presentation of the graphical interface

• Description of software, functionalities, parameters

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2. EQUIPMENT DESCRIPTION

The equipment's design is modular and transportable; it is integrated in transportation cases. It includes among others a control case and maximum five identical injection cases. The number of injection cases depends on the current required for the test planned, considering that each injection module is able to supply a maximum current of 2500A. Each module's connecting cables are included in their respective case.

2.1. The ICK20 control module

This module, located in a case, includes two elements :

2.1.1. A Man Machine Interface

It is composed of a PC located in a 1U high slide drawer. From the PC screen, you can :

• Supervise the operation of each connected injector, especially the good condition of its electrical connection to the control module and to the main supply, its load state and a possible failure occurred during an injection.

• Create in graphical form the selected instruction current wave to realize the test.

• Realize the injection by "left click" with confirmation by "Enter".

• View the current shape really injected during the test, upon selection, on a separate graph or stacked on the instruction; during a circuit-breaker test, the opening time of this one appears clearly on the return wave.

• Store results of tests and various instructions for future use.

2.1.2. A control module situated in a 2U rack

This module is electrically connected on the front panel to 230V main supply by means of cables. It has a power on switch and eight connectors numbered from 1 to 8 that allow creating a link by means of a cable specific for each injector used for the test. This control rack, which is connected by USB link to the PC, realizes in fact a supervision and control interface electrically insulated between the PC and the injectors.

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2.2. IJK20 injection modules

The injection module has the form of a 3U 19" rack situated in a case. This case is provided with two front and rear covers; it allows this way storing on the rear part the two power cables, the connecting cable to the control module and the mains cable. A 10 points connector is present on the injection module front panel to allow connection to the control module. On the front panel, you can also note two power terminals, a red and a black one, that will be connected to the tested device by means of "push pull" connectors of power cables of respective colors. Two connectors, input and output, situated on the front panel allow to chain the power supply of X modules dedicated to testing. The first injector is connected by means of its input switch to a mains switch by means of a standard cord; the mains is then chained towards the other modules by means of the various mains input, output switches and the short, male female mains cables. When an injection module is properly connected, on one hand to 230V mains and, on the other hand, to control module, and when the latter and the PC are under power, a waiting time of about 10 minutes is required to realize the first load necessary to perform tests. After a first injection, a maximum reload duration of one minute is required before realizing a new injection.

2.3. Connection

1) Injection modules can equally be placed flat, stacked or put vertically, with horizontal front panel, one next the other, next to the device to be tested.

2) Power cables are 3 meters long.

Connect, on one hand, power cables marked in red and black to power terminals of the same colors on each injector module used; a male female foolproofing allows to avoid polarity reversal.

3) Connect, on the other hand, other cable ends to the device to be tested by means of

two copper plates (one + one -) especially arranged for the test and equipped one with terminals and the other with pin-head adapters compatible with the cables and sufficient in number to connect the quantity of modules required for the test.

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4) Connect to 50Hz alternating 230V mains the first module by means of a mains cord

usually available in the control case, and then chain all the other injectors at "input" and "output" mains switches level, by means of "male" and "female" mains cables present in each injector case.

5) Connect by means of the multipair linking cable the "control" input of each injector

module to one of the eight "?" outputs of the control module. There is no connection sequence to follow; for instance the injector module that will be connected to output "4" shall be considered as being injector n°"4" at visual interface level.

6) For usability, the control case can be located at about 3 meters far from the injectors

group (length of multipair connecting cables). 7) Connect also the control rack to 50Hz alternating 230V mains by means of the second

mains cord located in the control case. 8) Power on the unit through M A switch on the front panel of the control device.

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3. SOFTWARE DESCRIPTION

3.1. Starting-up

To start the program, the user must execute the « IDC.exe » file, situated in the installation folder (ProgramFiles…) or use the shortcut on the « Desktop ». The software main window is composed of :

− A table of LEDs showing injectors status, − Graphs showing sent and received curves, − A tool for generating short-circuit or constant curve on a given maximum intensity, − A panel allowing to select the number of required injectors and to realize the

injections.

The detection and the connection with the control module are carried out automatically at starting-up or when powering on the control module. If the control module is not detected, check whether cables, power supply and USB are properly connected and whether the module is on.

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3.2. The menu

• File « Open » allows loading a file containing points that show a current curve. The currently supported file type is « .ddl » (see § 3.4.2). « Save » allows saving the resulting curve or the theoretical curve in a file at « .ddl » format. « Close » closes the program.

• Configuration « Graphs » allows merging both graphs in a single one. « Log book » displays messages on the operating status of the control module. « Language » language selection (French, English, Spanish). « Calibration » displays a panel allowing to calibrate the control module.

• Module

« Injection » realizes the curve injection (see § 3.5).

3.3. Injectors status

Injectors status is represented by the following panel :

This panel displays for each injector the 3 status in which an injector can be :

• Injector connected (green) / not connected (grey)

• Injector charged (green) / discharged (red)

• Error (red on) / no error (grey)

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3.4. Current curve loading

Curve loading can be performed in two ways. Curves can be generated either using a parameterizable function, simulating a resistant circuit without any train on the line, or loading the DDL file containing a current curve representation.

3.4.1. Parameterizable function loading

The following panel allows parameterizing a function generating either a short circuit curve or a constant on a given maximum current intensity.

To generate a short circuit curve, default displayed parameters are the typical values of a 3kV network (Belgium). These include following parameters :

• Voltage of the substation in Volts • Inductance in kilometres of catenary circuit + return by rails and ground • Resistance in kilometres of the same circuit • Fault resistance • Distance in kilometres between fault and substation

The number of injectors required to inject the current curve is then automatically configured.

3.4.2. File loading

3.4.2.1. Files format

The application allows loading files with a « .dll » extension. « .dll » files are provided by GILLAM-FEi and present on the computer driving the control module.

3.4.2.2. File opening

File loading can be realized in several ways : • Through menu « File » � « Open », • Through icon , • Selecting the file in Windows and dragging it on the application main window

(Drag and drop).

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3.5. Current curve injection

To realize an injection, following conditions should be respected :

• A curve must be loaded; • The number of connected and ready injectors must be sufficient to provide the

current quantity required to generate the current curve.

When above mentioned conditions are fulfilled, the user is able to realize the injection, either by clicking on « Injection » or by following the menu option. After the injection, the curve of the current really injected is displayed in the second graph. In case of error during the injection, a restart of control module and software is imperative.

3.6. Curve saving

The software allows saving the result of an injected curve at « .ddl » format. Recording is performed through « File » � « Save » menu or through icon. A curve can be saved as an image. Graph saving in an image format is realized by right-ckick on the selected curve and by selecting « Save image as … » in the pop-up menu.

3.7. Language configuration

The application can be configured in different languages (French, English, Spanish) through the « language selection » panel accessible through the menu.

Max intensity according to injectors number

Records the selection permanently.

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3.8. Curves display configuration

By default, each curve is drawn in a separate area as shown below :

Through the « Configuration » menu, you can configure curves display to compare both curves on the same graph; you just have to select « Overwritten » in the « Configuration » � « Graphs » menu to get the following display :

3.9. Calibration

The calibration panel, accessible from the « Configuration » menu, allows to send a 4mA or 20mA signal on the eight outputs of the control module.